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Senior Project Report PV Hybrid Inverter & BESS

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Senior Project Report PV Hybrid Inverter & BESS Electrical Engineering Department California Polytechnic State University Senior Project Report PV Hybrid Inverter & BESS June 14th, 2019 William Dresser Owen McKenzie Derek Seaman Jacob Sussex Jonathan Wharton Professor William Ahlgren & Professor Ali Dehghan Banadaki Table of Contents Table of Contents 1 List of Tables 2 List of Figures 2 Abstract 3 1. General Introduction and Background: 4 2. Overview of Customer Need: 6 3. Project Description: 6 4. Market Research: 7 5. Customer Archetype: 8 6. Market Description: 9 7. Business Model Canvas Graphic: 12 8. Marketing Requirements: 13 9. Block Diagram: 16 ​ 10. Requirements: 16 ​ 11. Cost Analysis: 17 ​ 12. Team Coordination: 18 ​ 13. Design Iterations and SolidWorks 18 ​ 14.Assembly Iteration and Challenges 26 15. Project Significance and Applications 28 ​ 16. Peripherals 29 17. Project Continuation 31 18. Department Future 33 19. References: 34 1 Appendix A: Senior Project Analysis 36 Appendix B: Preliminary Design Analysis 45 List of Tables Table 1 Customer Archetype Table 2 Number of Panels in Configuration and Relevant Metrics Table 3 Requirements Table 4 Bill of Materials Table 5 Budget for Unistrut Cart Design Table 6 Budget for 8020 Cart Design Table 7 Budget for Electrical Components List of Figures Figure 1 Photovoltaic Cell in a Solar Panel Figure 2 Cost Trend of Solar Power Figure 3 Diagram of Tabuchi EIBS16GU2 Energy Flow Figure 4 Business Model Canvas Figure 5 Graphical Representation of the Number of Panels in PV Array vs Charge Time Figure 6 Block Diagram of How the Tabuchi System will be Implemented Figure 7 First Iteration of 8020 Cart in SolidWorks Figure 8 2D CAD View of First 8020 Cart Design Figure 9 2nd Iteration of Cart with Unistrut 2 Figure 10 Final Cart Design Figure 11 Phase Converter to be Purchased in Future Abstract The storage of energy from renewable sources such as photovoltaic based systems is a growing market, with 36 MWh of storage installed in Q1 of 2018. A report from EnergySage earlier this year states that in 2017, 74% of residential solar owners were also interested in energy storage systems. Mainstream systems like Tesla’s Powerwall are competing with other lithium-ion based storage systems from a wide number of providers on the market today. Short term and long term data collection on a system like this could be useful in designing future systems which perform better than the current market offerings. This project seeks to install and operate the Tabuchi EIBS that the Cal Poly Electrical Engineering department currently owns. EIBS stands for Eco Intelligent Battery System, and it is meant to be used in conjunction with a photovoltaic array in a residence. This kind of system is a parallel to a source like a Tesla Powerwall, and uses two 10 kWh Li-Ion batteries. As of right now the system is being rolled between room 102 and room 146 of building 20, where it is assembled and ready to be energized. This team would like to assemble, mount, and integrate this system into the EE building micro-grid allowing for future students to test the storage and economical benefit of this system while connected to either the grid or a photovoltaic array. Our first priority was mounting the system on a mobile platform to enable flexible usage wherever its power would be most beneficial. After installation, time permitting, we wish to measure characteristics such as battery life, charge time, switching time, maximum throughput and how efficiently the batteries charge and discharge the energy to be stored. 3 1. General Introduction and Background: Solar power is becoming more and more popular due to rising efficiencies and cost effectiveness. In fact, renewable energy generation grew by 167 GW in 2017, representing a stable growth rate of 8.3% according to the SDG Knowledge Hub, a site that documents sustainable development [8]. Solar panels are large panels that are made of many smaller units called photovoltaic cells. These cells use the photons irradiated by the sun to free electrons from the atoms in the photovoltaic cell which generates a current that can be used to charge batteries, power a house, or any other application that requires reasonable amounts of electrical energy. Figure 1: Photovoltaic Cells in a Solar Panel When solar panels first came out around 1977 the price for the electricity they produced was about $76.67 per watt, but as of 2013 solar costs about $0.74 per watt (according to Clean Technica) which makes solar a much better investment today. 4 Figure 2: Cost Trend of Solar Power To really get the most out of a photovoltaic system, an energy storage system can be used to capture the energy that is generated by the photovoltaics. By doing this, the energy can then be stored and either sold back to the electric company if it is not used, or the energy can be used during peak hours and be replenished the following day. The benefit of using the energy during peak periods of electricity usage is that the customer can typically pay less for electricity than they normally would be if they were taking power from the grid. In both cases the resident or business saves money compared to the usual practice of relying entirely on the grid for power consumption. 5 Our project is a system that integrates both photovoltaic and grid-based power. The product will have an inverter and high-capacity batteries mounted on a mobile platform so that the energy can be used in different locations, or to power systems that cannot be turned off. EIBS in general will allow customers to save money by running off of battery power during peak electricity hours, but in our case we hope to use the system primarily as an education and research tool. 2. Overview of Customer Need: With the usage of renewable energy becoming more and more prevalent, a method for storing excess power generated via renewable sources is an obvious next step. Without a storage system, customers with solar panels are forced to rely on grid power during the evening, or when weather restricts daylight hours. A storage platform enables the user to save money and stay self-reliant under a variety of adverse conditions. In addition, our system focuses on portability, with the inverter and batteries able to be transported separately and easily for testing in multiple locations. This allows users the ability to transport a power source directly to the electronics to be powered without having to attach the system to the building's internal wiring and the grid. 3. Project Description: Our system will consist of the Tabuchi Electric EIBS Hybrid Inverter and Storage Batteries mounted to a portable skeleton and it will be wired for use in pulling from a DC or AC 6 power source, such as a solar array or the grid. Our system will take a DC input of 70-550V or an AC input directly off the grid, store the power in two 9.89kWh batteries, and return the power at the standard 120/240V, 60Hz. Via the control panels, power can be inputed or distributed on command, either in on-grid operation or running as a stand alone system. Finally, if setup and installation goes smoothly, we plan to measure capacity, charge and discharge rates, and storage efficiency. However, after reaching the final step of testing the system we found that it had to be plugged into both a DC power source and the AC grid for the batteries and inverter to function. Due to running out of time we were unable to test the system fully but we were able to confirm that it was wired correctly and that the inverter and batteries turn on. Figure 3: Tabuchi Diagram of EIBS16GU2 Energy Flow The project is mobile, with the batteries and inverter mounted separately. With this setup, they can be transported to any accessible site and allowed to charge, then moved to a secondary location for usage. This is accomplished with quick attach-detach cables that interconnect the 7 separate parts. The important thing to note about the Tabuchi system is that when attached the grid, power will not be allowed to flow back to the grid. If power were able to flow back to the grid then we would have to get certified technicians to set the system up for us, but luckily this is no problem and we can hook to the system to the grid without having to worry about sending power back. 4. Market Research: The Tabuchi system available for use is approximately 20 kWh in energy capacity and includes an inverter, battery connection box, remote controller, and a ten year warranty. The invoice accompanying this product lists the sale price to Cal Poly as $12,000. The Tesla Powerwall is the direct competition of Tabuchi Electric’s EIBS, with a prominent presence in North America. Looking at the current iteration of Tesla’s website, a single powerwall unit has a capacity of 13.5 kWh, includes an inverter, has a 10 year warranty, and can be expanded using multiple connected units. Tesla only sells the powerwall as a set of two for $13,400 with $1,100 of supporting hardware required for a total cost of $14,500. Costs of $12,000/20 kWh and $7,200/13.5 kWh for Tabuchi EIBS16GU2 and Tesla Powerwall, respectively, equate to $600/1 kWh for Tabuchi and $533.33/1 kWh for Tesla. In the North American market there is no competition in name recognition between the two, other companies with name recognition like LG are releasing similar systems in 2018/2019.
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